Combined 3D Services
3D Printing for Aerospace: Prototypes, Flight Hardware, and Tooling
By Mike Moussa, PE — Aerospace has been an early adopter of additive manufacturing, and for good reason. Here’s how we support aerospace projects from concept through flight-ready hardware.
Aerospace Applications
Rapid Prototyping for Aerostructures
Test fit brackets, ducting, fairings, and structural concepts before committing to machined aluminum or composite layup. Iterate in hours at 1/10th the cost of traditional methods.
Flight-Rated Ducting and Brackets (ULTEM 9085)
ULTEM 9085 is FST (flame, smoke, toxicity) rated and approved for aircraft cabin interiors per FAR 25.853. We 3D print production ducting, cable management, and brackets that fly.
Autoclave and Composite Tooling
3D printed tools for composite layup that survive autoclave cycles (350°F, 100 PSI). ULTEM and high-temp materials replace expensive Invar tooling for short runs and development.
Wind Tunnel Models
SLA and SLS printed wind tunnel models with smooth surfaces and fine details. Quickly test aerodynamic concepts without spending weeks in a machine shop.
Conformal Cooling Channels
3D printing enables internal cooling channels that follow the part contour — impossible with traditional machining. Applications in heat exchangers, electronics cooling, and thermal management.
Materials for Aerospace
- ULTEM 9085 — FST rated, flight-approved. The go-to for aircraft cabin parts. Handles 350°F continuous.
- ULTEM 1010 — Higher strength and heat resistance than 9085. Autoclave-compatible.
- Carbon-Fiber PEEK — Extreme performance. Near-metal strength with weight savings.
- Nylon 12 (SLS) — Non-structural components, cable routing, fixtures.
- Aluminum (CNC) — When you need metal. 6061-T6 and 7075-T6 machined to AS9100 standards.
Quality and Traceability
- Material certificates and lot traceability available
- First article inspection reports (FAIR) per AS9102
- Dimensional inspection with CMM when required
- Process documentation for customer QMS integration
Get in Touch
We work with everyone from home-built aircraft builders to defense primes. Whatever your aerospace project, we can help with prototyping and low-volume manufacturing.